Concrete form bracket for use in casting a foundation wall integral with a floor

ABSTRACT

A concrete form bracket for a concrete form having an outer form wall and an inner form wall for defining an outer surface and an inner surface of a perimeter foundation wall. The bracket is a rigid, metal, frame member, having a first upright leg portion joined to the outer form wall, a second upright leg portion joined to the inner form wall, and a bridge portion connected between the first and second upright leg portions. The bracket has fastener apertures for fastening the first and second leg portions to wood material of the respective outer and inner form walls in a manner that allows the inner form wall to be suspended from the brackets which are in turn supported on the outer form wall such that the inner form wall is entirely supported on the outer form wall.

This application claims the benefit under 35 U.S.C. 119(e) of U.S. provisional application Ser. No. 62/615,736, filed Jan. 10, 2018.

FIELD OF THE INVENTION

The present invention relates to a concrete form bracket used for suspending an inner form wall relative to an outer form wall when the inner form wall is used to define the inner surface of a building foundation wall that is cast integrally with the floor of the building, for example when the foundation is required to define a chemical containment receptacle in a building for storing chemicals therein.

BACKGROUND

When constructing a building that is intended for storing or using certain types of chemicals therein, it is a common requirement for the building walls to be supported on a concrete foundation wall that is cast integrally with the concrete floor of the building. The integral foundation wall is typically a short pony wall of only a few feet or less in height, but when cast integrally with the floor forms a receptacle with the floor that is capable of containing chemical spills.

Currently, when casting a concrete foundation wall integrally with the concrete floor of such a building, a custom framework of wood members is constructed and disposed of for each building being built. This results in a considerable amount of waste generated at each construction site. Furthermore, due to the requirement for the inner form wall to be fully suspended relative to the floor that is cast to extend below the inner form wall, highly skilled laborers are typically required to construct the framework to ensure proper alignment and support of the inner form wall relative to the outer form wall.

SUMMARY OF THE INVENTION

According to one aspect of the invention there is provided a concrete form bracket for a concrete form used in casting a building foundation defining a concrete chemical containment receptacle comprised of a concrete floor and a concrete foundation wall integrally cast with the floor while being capable of supporting walls of a building thereon, in which the concrete form includes an outer form wall defining an outer perimeter surface of the floor and an outer surface of the concrete foundation wall and an inner form wall defining an inner surface of the concrete foundation wall, the bracket comprising:

-   -   a rigid, metal, frame member, the frame member including a first         upright leg portion for joining to the outer form wall, a second         upright leg portion for joining to the inner form wall, and a         bridge portion connected between the first and second upright         leg portions,     -   the bridge portion spanning laterally between opposing first and         second ends a length which is greater than a combined width of         the outer form wall, the inner form wall, and a gap between in         the inner and outer forms walls that defines a wall thickness of         the foundation wall to be cast therebetween;     -   the first leg portion extending downwardly from the first end of         the bridge portion;     -   the first leg portion including fastener apertures therein so as         to be arranged for receiving fasteners to fasten the first leg         portion in fixed relation to the outer form wall;     -   the second leg portion extending downwardly from the second end         of the bridge portion so as to be parallel to and spaced apart         from the first leg portion; and     -   the second leg portion including fastener apertures therein so         as to be arranged for receiving fasteners to fasten the second         leg portion in fixed relation to the inner form wall.

Use of a rigid metal frame member with suitable fastener apertures on parallel and spaced apart first and second leg portions provides a reusable bracket which suspends an inner form wall relative to an outer form wall in a manner which allows for quick and accurate alignment therebetween to simplify the process of forming a building foundation capable of containing chemical spills.

Each of the leg portions may include (i) a main portion formed of plate material which is co-planar with the bridge portion and (ii) a flange portion protruding perpendicularly outward from the main portion along an innermost edge of the main portion that is nearest to the other leg portion. Typically, the fastener apertures are provided at least in the flange portions for fastening to the inner and outer form walls.

A bottom edge of the bridge portion spanning between the first leg portion and the second leg portion may include a first shoulder adjacent to the first leg portion and a second shoulder adjacent to the second leg portion which are co-linear with one another for abutment with a top end of the outer form wall and a top end of the inner form wall respectively. The bottom edge of the bridge portion may further comprise a central recessed portion between the first shoulder and the second shoulder which is raised upwardly in elevation relative to the first and second shoulders.

According to one embodiment of the invention, the first leg portion, the second leg portion and the bridge portion may be formed of a single, metal, plate member.

According to alternate embodiments, the bridge portion may comprise a first member joined integrally with the first leg portion and a second member joined integrally with the second leg portion in which the first member and the second member are selectively fastened to one another in a plurality of different mounting configurations corresponding to different lateral spacings between the first leg portion and the second leg portion.

The first member and the second member may be selectively coupled by a pair of pins coupled between the first and second members at laterally spaced apart positions in which each pin is fixed to one of the first and second members and is laterally slidable within a corresponding track in the other one of the first and second members. In this instance, each track may include (i) a linear portion receiving the pin therein for linear sliding in a lateral direction to vary a distance between the first and second leg portions, and (ii) a plurality of detents at spaced positions along one side of the track to receive the pin therein and retain the first and second members at a selected one of the different mounting configurations.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the invention will now be described in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view of a building foundation defining a chemical containment receptacle;

FIG. 2 is a top plan view of the concrete forms for forming the building foundation according to FIG. 1 into which the concrete form bracket according to the present invention are incorporated;

FIG. 3 is a sectional view along the line 3-3 of FIG. 1;

FIG. 4 is a perspective view of a first embodiment of the concrete form bracket according to the present invention;

FIG. 5 and FIG. 6 are front elevational and side elevational views of the concrete form bracket according to the first embodiment of FIG. 4;

FIG. 7 is a front elevational view a plate metal blank prior to folding into the concrete form bracket according to the first embodiment of FIG. 4;

FIG. 8 is a perspective view of a second embodiment of the concrete form bracket according to the present invention;

FIG. 9 is a front elevational view of the concrete form bracket according to the second embodiment of FIG. 8;

FIG. 10 and FIG. 11 are perspective and front elevational views of an outer portion of the concrete form bracket according to the second embodiment of FIG. 8;

FIG. 12 and FIG. 13 are perspective and front elevational views of an inner portion of the concrete form bracket according to the second embodiment of FIG. 8;

FIG. 14 and FIG. 15 are perspective and front elevational views of an outer portion of the concrete form bracket according to a third embodiment of the concrete form bracket.

In the drawings like characters of reference indicate corresponding parts in the different figures.

DETAILED DESCRIPTION

Referring to the accompanying figures there is illustrated a concrete form bracket generally indicated by reference numeral 10. Although several embodiments of the bracket 10 are described in the following and illustrated in the accompanying figures, the common features of the various embodiments will first be described.

In each instance the bracket 10 is typically used in forming a building foundation in which foundation walls 14 and a floor 16 are cast integrally with one another using concrete so as to define a chemical retaining receptacle. The foundation wall typically extends about the full perimeter of the floor to extend upwardly therefrom a height which may be only a few feet or less for example. The foundation wall is suited for supporting building walls 18 of a building thereon. A foundation wall of this type is commonly referred to as a pony wall.

When integrally joining the foundation wall to the floor, the floor typically extends deeper into the ground at a perimeter edge portion than through the remaining central portion of the floor so that the perimeter edge portion 20 of the floor is thicker in height where it joins with the base of the foundation wall.

Typical concrete forms for casting foundation walls integrally with a concrete floor include an outer form wall 22 at the outer side of the location of the foundation wall, and an inner form wall 24 for spanning the inner side of the foundation wall. More particularly the outer form wall 22 spans the combined height of the outer perimeter surface 26 of the concrete floor and the height of the outer surface 28 of the foundation wall extending upwardly above the upper surface of the floor in elevation. Typically, the ground about the location of the concrete forms is excavated to allow the foundation wall to extend below grade. The outer form wall 22 is typically formed of dimensional lumber secured in a vertical orientation about the perimeter of the concrete structure using a plurality of ground stakes 30 which are generally evenly spaced apart about the full perimeter of the concrete forms. The top edge of the outer form wall defines the top end of the resulting concrete foundation wall formed by the concrete forms.

The inner form wall is also formed of dimensional lumber and is intended to span the full height that the foundation wall extends upwardly from the upper surface of the floor. The top edge of the inner form wall lies in a common horizontal plane with the top edge of the outer form wall so as to also terminate at the top end of the concrete foundation wall. The inner form wall is suspended relative to the outer form wall such that the bottom edge of the inner form wall terminates in a common plane with the upper surface of the finished concrete for structure. In this instance, before pouring of concrete into the concrete forms, the bottom edge of the inner form wall is suspended to float spaced above the ground surface therebelow upon which concrete for the floor is poured. Prior to pouring of concrete into the concrete forms, elongate metal bars for reinforcement, known as rebars, are positioned within the cavity between the inner and outer form walls as well as being connected from the cavity between the form walls to the space where the concrete floor is to be cast.

Each concrete form bracket 10 according to the present invention is joined between the outer form wall and the inner form wall such that the resulting concrete form work includes a plurality of the brackets 10 at evenly spaced apart positions about the full perimeter of the concrete structure.

Each concrete form bracket 10 includes a first leg portion 32 to be fastened in fixed relation to the outer form wall 22, a second leg portion 34 to be fastened in fixed relation to the inner form wall 24, and a bridge portion 36 that spans laterally between the top ends of the first and second leg portions across the full width of the formwork between the inner form wall and the outer form wall.

Each bracket 10 is formed of plate metal material. More particularly each leg portion of the bracket includes (i) a main portion 38 spanning the full height of the bracket and which lies in a common plane with the bridge portion 36 so as to lie coplanar within a common vertical plane oriented perpendicularly to a lengthwise direction of the foundation wall being formed, and (ii) a flange portion 40 which is folded to protrude perpendicularly outward from the main portion along the innermost edge of the main portion that is nearest to the other leg portion, along the full height thereof between the bridge portion and the bottom end of the leg portion. The flange portions 40 of the first and second leg portions are thus oriented parallel to one another for parallel abutment against corresponding surfaces at the outer and inner sides respectively of the formwork.

The first upright leg portion is greater in height than the second leg portion.

Each leg portion further includes a plurality of fastener apertures formed therein at vertically spaced positions along the length thereof so as to be suitable for receiving fasteners therethrough for fastening the leg portions to the respective inner and outer form walls. More particularly, the single row of vertically spaced apart fastener apertures is provided within each flange portion 40.

The main portion 38 of the first leg portion is also provided with an additional row of fastener apertures. In this manner, when the main portion is abutted against the side surface of one of the stakes 30, fasteners can be used to secure the first leg portion relative to the outer form wall by either fastening through the main portion to a side surface of one of the stakes, or fastening through the flange portion to the outer surface of the outer form wall, or a combination thereof.

As described above, the bridge portion lies in a common plane with the main portions 38 of the two leg portions. The bottom edge of the assembled bridge portion is shaped to define a first shoulder 42 adjacent the first leg portion which lies perpendicular to the vertical orientation of an upright axis of the leg portion such that the first shoulder is generally horizontal. The bottom edge also includes a second shoulder 44 adjacent the second leg portion which lies perpendicular to the vertical orientation of the upright axis of the leg portion such that the second shoulder is also generally horizontal and co-linear with the first shoulder.

The bottom edge of the bridge portion further includes a central recess 46 spanning laterally between the first and second shoulders which is raised in elevation relative to the first and second shoulders across the full width therebetween. In this manner the central recess 46 is intended to span the full width of the gap between the inner and outer form walls that defines the foundation wall of the concrete structure. The central recess 46 provides access for trowels and other leveling tools for finishing the top surface of the foundation wall formed by the inner and outer form walls.

In use, the outer form wall is typically first erected using the stakes 30 at the outer surface of the outer form wall about the full perimeter of the concrete structure to be formed. A plurality of the brackets are then secured about the perimeter of the outer form wall so that the inner form wall can be subsequently fastened across the second leg portions of the brackets in a manner which suspends the inner form wall relative to the outer form wall with the bottom edge of the inner form wall being aligned with the desired finished height of the floor to be cast. Concrete is then filled into the form to be flush at the top side of the cavity between the inner and outer form walls. The concrete is also poured into the central floor space such that the upper surface of the concrete is flush and coplanar with the bottom edge of the inner form wall.

Turning now more particularly to the first embodiment of FIGS. 1 through 7, each bracket 10 in this instance is formed of a single sheet metal blank according to FIG. 7. The bracket in this instance is fixed in size, however it can be fastened to different heights of inner and outer form walls for casting different foundation wall heights at a predetermined wall thickness. The first shoulder 42 spans a greater distance in the lateral direction than the second shoulder in this instance. This is particularly suited for mounting of the bracket at the location of one of the stakes 30 as shown in FIG. 3 so that the first shoulder spans a combined thickness of the stake and the outer form wall in the lateral direction. The cavity between the inner and outer form walls remains unobstructed by the shoulders by providing a recess which is sized to span the full width of the cavity.

According to a second embodiment shown in FIGS. 8 through 13 and a third embodiment in FIGS. 14 and 15, the bracket 10 may alternatively be adjustable in lateral width between the first and second leg portions to allow the brackets to be used for casting different wall thicknesses. In these instances, the overall bracket member is formed of two plates including an outer plate 50 defined by the first leg portion and an outer section of the bridge portion and an inner plate 52 defined by the second leg portion and an inner section of the bridge portion. The outer plate 50 and the inner plate 52 overlap one another in parallel abutment to collectively form the bridge portion 36 when assembled together.

A pair of locating pins 54 are provided at laterally spaced apart positions along the bridge portion to assist in coupling the inner and outer plates relative to one another in the selected one of a plurality of different mounting configurations corresponding to different lateral widths of the bridge portion between the first and second leg portions respectively.

Each locating pin 54 is fixed to one of the inner plate or the outer plate for lateral sliding movement within a corresponding track 56 in the other plate. Each track includes a linear portion 58 which is horizontally oriented to allow the pin to be laterally slidable therein as the overall width of the bracket is varied, and a plurality of detents 60 at laterally spaced apart positions along one of the long edges of the linear portion of the track. When the track 56 is located on the inner plate, the detents extend upwardly from the linear portion of the track. Alternatively, when the track is provided on the outer plate, the detents extend downwardly from the linear portion of the track. In each instance, the inner plate is lifted upwardly relative to the outer plate that is fixed to the outer form wall to cause movement of the locating pins into the respective linear portions of the tracks respectively. The inner plate can then be displaced laterally relative to the outer plate to vary the overall width by sliding the pins within the respective linear portions of the tracks. Once a selected width has been reached, and both pins are aligned with corresponding detents 60, the inner plate is lowered relative to the outer plate to lock the pins within the respective detents and prevent further lateral adjustment of the inner plate relative to the outer plate.

In the illustrated embodiments, the outermost locating pin 54 is in fixed relation on the inner plate 52 for being received within a track on the outer plate 50 having detents extending downwardly from the linear portion of the track. Alternatively, the innermost locating pin 54 is in fixed relation on the outer plate 50 for being received within a track on the inner plate 52 having detents extending upwardly from the linear portion of the track.

In the second embodiment of FIGS. 8 through 13, the first shoulder 42 is sized to be greater in length than the second shoulder 44, for example to be suited for spanning over the stakes 30 at the outer side of the outer form wall similarly to the first embodiment.

Alternatively, in the third embodiment of FIGS. 14 and 15, the outer plate 50 differs in that the first shoulder 42 is sized to be approximately equal in length to the second shoulder 44 of the inner plate 52. The configuration is well suited for mounting of the first leg portion directly to the outer surface of the sheet material forming the outer form wall so that the apertures in the main portion 38 may be used for securement to a side surface of the stake instead of using the fasteners in the flange for securement to the outer surface of the stake for example. The inner plate 52 according to the third embodiment is identical to the inner plate of the second embodiment as shown and described in FIGS. 12 and 13.

Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. 

1. A concrete form bracket for a concrete form used in casting a building foundation defining a concrete chemical containment receptacle comprised of a concrete floor and a concrete foundation wall integrally cast with the floor while being capable of supporting walls of a building thereon, in which the concrete form includes an outer form wall defining an outer perimeter surface of the floor and an outer surface of the concrete foundation wall and an inner form wall defining an inner surface of the concrete foundation wall, the bracket comprising: a rigid, metal, frame member, the frame member including a first upright leg portion for joining to the outer form wall, a second upright leg portion for joining to the inner form wall, and a bridge portion connected between the first and second upright leg portions, the bridge portion spanning laterally between opposing first and second ends a length which is greater than a combined width of the outer form wall, the inner form wall, and a gap between in the inner and outer form walls that defines a wall thickness of the foundation wall to be cast therebetween; the first leg portion extending downwardly from the first end of the bridge portion; the first leg portion including fastener apertures therein so as to be arranged for receiving fasteners to fasten the first leg portion in fixed relation to the outer form wall; the second leg portion extending downwardly from the second end of the bridge portion so as to be parallel to and spaced apart from the first leg portion; and the second leg portion including fastener apertures therein so as to be arranged for receiving fasteners to fasten the second leg portion in fixed relation to the inner form wall.
 2. The bracket according to claim 1 wherein the bridge portion is formed of flat, plate material which is parallel to an upright axis of each of the first and second leg portions.
 3. The bracket according to claim 1 wherein the first leg portion comprises a main portion formed of plate material which is co-planar with the bridge portion and a flange portion protruding perpendicularly outward from the main portion along an innermost edge of the main portion that is nearest to the second leg portion.
 4. The bracket according to claim 3 wherein at least some of the fastener apertures are located in the flange portion.
 5. The bracket according to claim 3 wherein at least some of the fastener apertures are located in the main portion.
 6. The bracket according to claim 3 wherein the flange portion of the first leg portion spans a full height of the main portion between a bottom end of the first leg portion and the bridge portion.
 7. The bracket according to claim 1 wherein the second leg portion comprises a main portion formed of plate material which is co-planar with the bridge portion and a flange portion protruding perpendicularly outward from the main portion along an innermost edge of the main portion that is nearest to the first leg portion.
 8. The bracket according to claim 7 wherein at least some of the fastener apertures are located in the flange portion.
 9. The bracket according to claim 7 wherein the flange portion of the second leg portion spans a full height of the main portion between a bottom end of the first leg portion and the bridge portion.
 10. The bracket according to claim 1 wherein the first leg portion is greater in height than the second leg portion.
 11. The bracket according to claim 1 wherein a bottom edge of the bridge portion spanning between the first leg portion and the second leg portion includes a first shoulder adjacent to the first leg portion and a second shoulder adjacent to the second leg portion which are co-linear with one another for abutment with a top end of the outer form wall and a top end of the inner form wall respectively.
 12. The bracket according to claim 11 wherein the bottom edge of the bridge portion further comprises a central recessed portion between the first shoulder and the second shoulder which is raised upwardly in elevation relative to the first and second shoulders.
 13. The bracket according to claim 1 wherein the bridge portion comprises a first member joined integrally with the first leg portion and a second member joined integrally with the second leg portion, the first member and the second member being selectively fastened to one another in a plurality of different mounting configurations corresponding to different lateral spacings between the first leg portion and the second leg portion.
 14. The bracket according to claim 13 wherein each of the first member and the second member comprises a flat plate member which is co-planar with a main portion of the respective leg portion, the flat plate members of the bridge member being selectively coupled in parallel abutment with one another.
 15. The bracket according to claim 13 wherein the first member and the second member are selectively coupled by a pair of pins coupled between the first and second members at laterally spaced apart positions, each pin being fixed to one of the first and second members and being laterally slidable within a corresponding track in the other one of the first and second members.
 16. The bracket according to claim 15 wherein each track includes a linear portion receiving the pin therein for linear sliding in a lateral direction to vary a distance between the first and second leg portions, and a plurality of detents at spaced positions along one side of the track to receive the pin therein and retain the first and second members at a selected one of the different mounting configurations. 